Weld Signature Shape Analysis for Short-Duration Quality Detection
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Solution Overview
Problem
Existing weld quality determination methods, particularly for short-duration welds, are inaccurate due to the instability of welding parameters, as they require a steady state to characterize the weld, which short-duration welds may never reach.
Innovation Solution
A method that captures and compares the shape of weld signatures to a reference signature, determining a weld fault condition based on the shape difference, allowing for accurate quality assessment regardless of parameter stability, and switches between shape-based and parameter value-based analysis routines based on welding duration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If parameter value-based weld quality analysis is used, then weld quality can be determined for steady-state welding parameters, but the method becomes inaccurate for short-duration welds where parameters never reach steady state
Solution Approach 1:
The patent transitions from static parameter value analysis to dynamic shape-based analysis. Instead of comparing fixed parameter values against thresholds, the system captures the temporal evolution of welding parameters as signatures and compares their shapes. This dynamic approach allows accurate characterization of both steady-state and transient welding processes, resolving the contradiction between measurement precision for steady-state parameters and adaptability to short-duration welds.
Solution Approach 2:
The patent fundamentally changes the analysis parameter from absolute parameter values to shape characteristics of parameter signatures over time. By transforming the data representation from scalar values to temporal profiles, the system can evaluate weld quality based on the pattern and evolution of parameters rather than their absolute magnitudes, enabling accurate assessment across different welding durations.
2Adaptability or versatility
If shape-based weld signature analysis is used, then accurate quality determination is achieved for short-duration welds, but the analysis complexity increases compared to simple parameter value comparison
Solution Approach 1:
The patent creates reference copies of weld signatures from known good welds and uses these as templates for comparison. Instead of implementing complex theoretical models, the system captures actual signature patterns from acceptable welds and compares new welds against these empirical references. This copying approach simplifies the analysis while maintaining high adaptability across different weld durations.
Solution Approach 2:
The patent performs preliminary capture and storage of reference weld signatures before actual quality determination. By pre-establishing reference profiles from acceptable welds, the system prepares comparison templates in advance, reducing the computational complexity during real-time quality assessment while maintaining versatility across different weld types and durations.
Data Source
AI summary
A method of determining weld quality includes the step of providing a reference weld signature having a first shape. A weld signature of a welding parameter is captured, wherein the weld signature of the welding parameter has a second shape. The first shape is automatically compared to the second shape and a weld signature shape difference between the first shape and the second shape is determined. A weld fault condition is determined based on the weld signature shape difference.